Measurement of maintenance planning and control effectiveness using the Lean approach

Ineffective maintenance management can result in a backlog of maintenance work orders, inefficient activity prioritisations, and unnecessary outages. Making a strategic decision is challenging due to traditional procedures that only treated maintenance at a tactical level. Usually, the key performance indicator (KPI) measured for maintenance management is related to work order compliance. However, there is still less work focusing on measuring the effectiveness of Maintenance Planning and Control (MPC) processes. This paper aims to showcase a measurement of the maintenance effectiveness at offshore facilities using Lean methodology by measuring the lead time of sub-processes of MPC activities to evaluate existing practices, identify gaps and develop key recommendations. To this end, the lead time of the baseline MPC process is analysed and benchmarked with that of the improved MPC where new parameters to monitor and verify the process efficiency are included. The results show that a lead time improvement of close to 60% was achieved with the proposed methodology.